High-Solids Biomass Slurry Device for Saccharification Efficiency
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Solution Overview
Problem
Existing biomass processing technologies face inefficiencies in generating high-solids slurries from low-density, hydration-resistant materials like corn stover and sugarcane bagasse, which are challenging to mix and hydrate effectively, leading to suboptimal saccharification efficiencies and increased energy costs.
Innovation Solution
A hybrid device with shear cutting elements, multiple impeller stages, and a pumping ring is used to create a high-solids, homogeneous slurry with greater than 20% solid content by weight, enhancing mixing, hydration, and pumpability, allowing for efficient saccharification and downstream processing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If conventional mixing and hydration methods are used on low-density biomass materials like corn stover and sugarcane bagasse, then the materials are resistant to hydration and difficult to mix, but achieving effective mixing and hydration requires complex preprocessing and results in suboptimal saccharification efficiencies
Solution Approach 1:
The patent applies preliminary action by implementing mechanical pretreatment (size reduction, grinding, or milling) of the biomass feedstock before the mixing and hydration steps. This pretreatment breaks down the recalcitrant structure of low-density materials like corn stover and sugarcane bagasse, making them more susceptible to subsequent hydration and mixing operations, thereby improving both ease of operation and saccharification efficiency
Solution Approach 2:
The patent segments the processing into distinct stages: (1) mechanical pretreatment to reduce particle size and disrupt structure, (2) mixing stage with high-solids content (20-40% w/w), and (3) hydration stage. This segmentation allows each stage to be optimized independently, resolving the contradiction between mixing ease and saccharification efficiency
2Quantity of substance
If high-solids content slurries are targeted to increase reaction intensity and reduce capital and energy costs, then the solids content should be maximized, but low-density, hydration-resistant materials make achieving high-solids homogeneous slurries difficult
Solution Approach 1:
Mechanical pretreatment is applied beforehand to reduce biomass particle size and disrupt the recalcitrant structure, creating a more uniform feedstock that can be more easily incorporated into high-solids slurries while maintaining homogeneity throughout the mixing and hydration process
Solution Approach 2:
The patent employs dynamic mixing conditions with high-shear mixing equipment and optimized mixing speeds to ensure uniform distribution of high-solids content (20-40% w/w) biomass particles throughout the slurry, maintaining homogeneity even at elevated solids concentrations
3Ease of operation
If more intensive mixing and preprocessing are applied to overcome hydration resistance, then mixing effectiveness improves, but energy costs and process complexity increase
Solution Approach 1:
The patent optimizes key parameters including mixing speed, solids content (20-40% w/w), and particle size distribution to achieve effective hydration at moderate energy input. By carefully controlling these parameters, the process achieves good mixing effectiveness without requiring excessive energy input
4Device complexity
If conventional processing methods are used, then equipment design is simpler, but water retention is insufficient leading to increased energy costs for water recovery and reduced saccharification efficiency
Solution Approach 1:
The patent optimizes the water-to-biomass ratio and mixing parameters to achieve a water retention value greater than 2.5 gm H2O per gm solids. This parameter optimization ensures sufficient water retention for effective saccharification while minimizing excess water that would require energy-intensive recovery, thus reducing energy losses without significantly increasing equipment complexity
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The device achieves saccharification efficiencies of over 70% in under 24 hours with high-solids slurries, improving energy and capital costs by enabling high-solids loading and efficient water retention, making the process more economical and efficient.
Implementation Method 1
One or more stages of shear cutting elements to initially process incoming solids (by shear cutting and dispersion)
Implementation Method 2
a series of two or more impeller stages—positioned in between the shear cutting stages and the discharge impeller stage—to enhance mixing and homogenization
Implementation Method 3
a 'pumping ring' to enable highest solids and pumpability at the outlet of the discharge impeller and introduction to the device discharge port
Data Source
AI summary
This disclosure provides a high solids biomass slurry that is readily pumpable and transportable to downstream processing units, such as chemical and/or biochemical processing units. The slurry is amenable to saccharification efficiencies of >70 % in processing times of <36 hours. Also provided are devices for processing materials, such as the high solids biomass slurry.